Soccer helmet

ABSTRACT

A soccer helmet includes a generally dome-shaped padding layer and a generally dome-shaped shell layer fitting over and attached to the padding layer. The padding layer might have a substantially uniform thickness of approximately ⅜ inches. The shell layer is smooth and has some rigidity such that when the soccer helmet is being worn on a human head, the ball rebounds from the shell layer in about the same direction and with about the same speed, or with a greater speed, as the soccer ball would if rebounded off an unprotected human head. Therefore, the soccer helmet does not interfere with heading a soccer ball. The soccer helmet protects the head from repetitive blows due to, for example, heading. Furthermore, the soccer helmet protects the head from single event injuries such as collisions with goalposts, the ground, and other players&#39; head, knees, elbows, and feet.

BACKGROUND OF THE INVENTION

[0001] 1. The Field of the Invention

[0002] The present invention relates to apparel. Specifically, thepresent invention relates to a soccer helmet and method.

[0003] 2. The Prior State of the Art

[0004] This is a continuation of co-pending application Ser. No.09/311,538, filed May 13, 1999, entitled “Soccer Helmet” that isincorporated herein by reference.

[0005] 3. The Prior State of the Art

[0006] Soccer (also called “football”) is one of the world's mostpopular sports. Like many rigorous activities, soccer involves some riskof injury, including head injury. Obvious causes of head injury insoccer include head collisions with another player's head, elbow, knee,or foot. Head injuries may also occur when the head collides into a goalpost or when i the player falls head first onto the ground.

[0007] A less obvious, but apparently real, cause of head injury insoccer is the use of the head to direct a soccer ball in what istypically called a “header”. Several studies have shown that heading cancause minor cumulative brain damage. Soccer players who repeatedlyheaded the ball during their careers were found to have chronic changeson the electroencephalograms (EEGs) similar to the changes found inamateur boxers. These players were found to have chronic mild to severedeficits in attention, concentration, memory, and judgement. Childrenwho had less experience heading the soccer ball were found to havegreater changes in the EEGs.

[0008] Such head injuries, even if minor, can have a serious impact onthe quality of life. Nearly every aspect of living can be affected.Cognitive symptoms of head injury include difficulty in processinginformation, shortened attention span, inability to understand abstractconcepts, impaired decision-making ability, inability to shift mentaltasks or to follow multi-step directions, memory loss or impairment, andlanguage deficits. Perceptual symptoms include change in vision, hearingor sense of touch; loss of sense of time and space and spatialdisorientation; disorders of smell and taste; altered sense of balance;and increased pain sensitivity. Physical symptoms include persistentheadaches; extreme mental and/or physical fatigue; disorders ofmovement; seizure activity; impaired small motor control;photosensitivity; sleep disorders; paralysis; and speech that is notclear due to poor control of the muscles in the lips, tongue and jawand/or poor breathing patterns. Behavioral and emotional symptomsinclude irritability; impatience; reduced tolerance for stress; lack ofinitiative; dependence; failure to assume responsibility for one'sactions; denial of disability; lack of inhibition; inflexibility; andflattened or heightened emotional reactions. Needless to say, the effectof head injury on the quality of life is far reaching.

[0009] While the number of individuals participating in soccer is tooenormous to be known precisely, estimates have it that there were morethan 40 million amateur participants as of the late 1980s. It isanticipated that presently there are many more amateur participantsconsidering the increased popularity of soccer during the 1990s. Thus,considering the immense number of individuals participating in soccerworldwide, and considering the wide-ranging effect of head injury on thequality of life, even a slight risk of head injury in soccer has greatimpact upon world health.

[0010] A head guard aimed at providing a limited degree of headprotection in soccer is described in U.S. Pat. No. 4,698,852 issued toRomero on Oct. 13, 1987. The Romero device includes a resilient,rectangular contact portion for contacting and absorbing perspirationfrom the player's forehead, and a corresponding outer layer forfrictionally contacting the soccer ball.

[0011] The Romero device aims to protect the forehead from minor tearingand breaking of capillaries in the skin of the forehead. The Romerodevice does not disclose that it protects against more serious injuriessuch as repetitive or single event brain injuries or concussions.Furthermore, although a proper header is performed by striking theforehead against the ball, such headers are not always possible due tothe inexperience of the player or due to the heat of competition. Someevidence shows that these types of improper headers give rise to ahigher risk of head injury. Thus, the Romero device does not provideconsistent head protection, and provides no head protection for higherrisk headers in which the soccer ball impacts with areas other than theforehead. Furthermore, areas other than the forehead are left exposed toacute injury such as that resulting from head collisions with otherplayers or objects.

[0012] From a performance standpoint, the Romero device also mightactually interfere with heading if the soccer ball hits the edge of therectangular pad, rather than its center. The abrupt edge could reboundthe soccer ball in a direction much different than if the soccer ballrebounded off a smoother surface such as an unprotected head.

[0013] Helmets have conventionally been used in most sports whichinvolve a risk of head injury such as American football, baseball, icehockey, lacrosse, cycling, skiing, snowboarding, kayaking, equestriansports, and rock climbing. However, conventional helmets would seriouslyinterfere with heading and thus interfere with the very nature of thesport of soccer. Thus, conventional helmets are not used in soccer eventhough there is a significant risk of head injury.

[0014] Therefore, an apparatus and method are desired for providing morecomprehensive protection to a soccer player's head without interferingwith heading.

SUMMARY OF THE INVENTION

[0015] In accordance with the present invention, a soccer helmetincludes a generally dome-shaped padding layer and a generallydome-shaped shell layer fitting over and attached to the padding layer.The padding layer preferably has a substantially uniform thickness ofapproximately ⅜ inches. The shell layer is smooth and has some rigiditysuch that, when the soccer helmet is being worn on a human head, asoccer ball will rebound from the shell layer in substantially the samedirection, and with substantially the same speed, or with greater speed,as the ball would if rebounded off an unprotected head. Therefore, thesoccer helmet does not interfere with a header. A high friction materialmay be disposed on the forehead portion of the shell layer to allow forbetter control of the soccer ball.

[0016] A soccer helmet padding layer may be formed with a uniformthickness at an area corresponding to a human forehead. The thickness ofthe padding layer in other areas may vary according to the user'spreference. Furthermore, the padding layer may include channels on theinside surface to ventilate and control perspiration from a player'shead. A soccer helmet shell layer formed to fit over the soccer helmetpadding layer is attached to the soccer helmet padding layer. The soccerhelmet padding layer may be removed from the soccer helmet shell layerwithout damage to either the padding layer or shell layer.

[0017] Additional objects and advantages of the invention will be setforth in the description which follows, and in part will be obvious fromthe description, or may be learned by the practice of the invention. Theobjects and advantages of the invention may be realized and obtained bymeans of the instruments and combinations particularly pointed out inthe appended claims. These and other objects and features of the presentinvention will become more fully apparent from the following descriptionand appended claims, or may be learned by the practice of the inventionas set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] In order that the manner in which the above-recited and otheradvantages and objects of the invention are obtained, a more particulardescription of the invention briefly described above will be rendered byreference to specific embodiments thereof which are illustrated in theappended drawings. Understanding that these drawings depict only typicalembodiments of the invention and are not therefore to be consideredlimiting of its scope, the invention will be described and explainedwith additional specificity and detail through the use of theaccompanying drawings in which:

[0019]FIG. 1 shows a soccer helmet in accordance with the inventionsecured to a human head;

[0020]FIG. 2 is an exploded view of the soccer helmet of FIG. 1;

[0021]FIG. 3 is a cross-sectional view along cross section line 3-3 ofFIG. 1; and

[0022]FIG. 4 is a detailed view of portion 4 of FIG. 1 showing the chinstrap connected to the padding layer of FIG. 1.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] The invention is described below by using diagrams to illustratean embodiment of the present invention. Using the diagrams in thismanner to present the invention should not be construed as limiting ofits scope.

[0024] Referring to FIG. 1, a soccer helmet 10 is secured to a humanhead (H) using a chin strap 22. A dome-shaped outer shell layer 14embraces a dome-shaped padding layer 12, the padding layer 12substantially fitting over and conforming to the shape of the cranium ofthe human head (H). Thus, the shell layer 14 and padding layer 12distribute focused mechanical shocks received by the shell layer 14thereby protecting the human head (H). The surface of the shell layer 14is substantially smooth without significant protrusions that mightaffect the rebound direction of the soccer ball. Furthermore, thedome-shaped shell layer 14 is sufficiently rigid and resilient, whenworn on the human head (H), that the shell layer 14 rebounds the ballwith about the same speed, or with greater speed, than the ball wouldrebound if off an unprotected head. The thickness and material of theshell layer 14 and padding layer 12 are chosen as described below tobalance head protection (e.g., energy absorption properties) againstperformance (rebound direction and resiliency) such that the soccerhelmet protects the head without significantly interfering with heading.

[0025] The various components of the soccer helmet 10 are now describedin further detail with respect to FIG. 2 which shows the soccer helmet10 in exploded view. The padding layer 12 in the center of FIG. 2 iscomposed of, for example, a closed-cell foam such as Volara™ closed-cellpolyolefin foam supplied by Voltek, a division of Sekisui AmericaCorporation, located in Lawrence, Mass. The polyolefin foam making upthe padding layer 12 preferably has a substantially uniform thickness ofapproximately ⅜ inches. Although the padding layer 12 covers the entirecranium, the portion of uniform thickness may apply over the foreheadonly, over the forehead and crown only, or over the entire cranium. Thechoice of thickness of the padding layer 12 given a certain material isobtained by balancing two competing factors. On the one hand, thethicker the padding layer 12, the more energy the padding layer 12absorbs, and the more protection there is for the human head (H). On theother hand, the thinner the padding layer 12, the more natural the feelof the header. A thickness of approximately ⅜ inches provides onebalance of these competing factors for polyolefin foam. However, thethickness may range from {fraction (3/16)} inches or less to ⅞ inches ormore depending on the user's preference, the desired level of protectionand/or performance, and on the padding material used.

[0026] The padding layer 12 includes a major dome-shaped portion 12 athat covers the forehead, temples and crown of the human head (H). Aminor arcuate portion 12 c covers the rearward portion (e.g., lowerparietal region and/or upper neck) of the human head (H). A second minorarcuate portion 12 b covers a portion of the human head (H) between themajor dome-shaped portion 12 a and the first minor arcuate portion 12 c.Indentations 12 d, 12 e in the padding layer 12 are provided between theportions 12 a, 12 b, 12 c of the padding layer 12. Alternatively, afabric or other compressible medium connects the portions 12 a, 12 b, 12c. The shape of the padding layer 12 shown in FIG. 2 is obtained by amolding process such that the assembled padding layer 12 conformsgenerally to the shape of the human head (H). Padding layer 12 may alsohave channels formed in the surface facing the human head (H) so as toventilate and control perspiration from the human head (H).

[0027] The dome-shaped shell layer 14 is substantially the same shape asthe padding layer 12 so as to fit over the padding layer 12. Thedome-shaped shell layer 14 is composed of a thin layer of plastic suchas a 0.090 inch thick layer of polypropylene. Alternatively, the plasticmaterial may be fiber reinforced. The choice of material and thicknessdepends on two competing factors. If the shell layer 14 is too rigid,the soccer ball will be difficult to control and the shell layer 14 willnot be flexible enough to fit a wide range of head sizes as describedbelow. If the shell layer 14 is too soft, the soccer ball will reboundslower than off an unprotected head. The material and dimensions of theshell layer 14 (namely, a 0.090 inch thick layer of polypropylene)described above are just one balance of these competing factors. Othermaterials and thicknesses may be used according to the user's preferencefor control, flexibility, and rebound speed.

[0028] The dome-shaped shell layer 14 also has a major dome-shapedportion 14 a and two minor arcuate portions 14 b, 14 c corresponding tothe portions 12 a, 12 b, 12 c, respectively, of the padding layer 12.Slots 14 d, 14 e corresponding to the indentations 12 d, 12 e in thepadding layer 12 separate portions 14 a, 14 b, 14 c of the shell layer14 except at the center region 14′. Flexible tabs 28 a, 28 c connect theminor arcuate portions 14 b, 14 c of the shell layer 14 over the slot 14e. Flexible tabs 28 b, 28 d connect the minor arcuate portion 14 b ofthe shell layer 14 to the major portion 14 a of the shell layer 14 overthe slot 14 d. The shell layer 14 shown in FIGS. 1 and 2 may be formedby, for example, injection molding.

[0029] The configuration of the dome-shaped shell layer 14 permits thesoccer helmet 10 to accommodate a wide range of head sizes and shapes.For example, the soccer helmet 10 is flexible side-to-side,crown-to-back, and circumferentially.

[0030] The minor arcuate portions 14 b, 14 c of the shell layer 14 areflexible allowing their radius of curvature along their major direction(namely, side-to-side) to increase to accommodate wider head shapes. Themajor portion 14 a also has some flexibility side-to-side. Thus, thesoccer helmet 10 has flexibility side-to-side. The soccer helmet 10 mayalso be flexed crown-to-back thereby increasing the width of the slots14 d and 14 e, and thereby stretching tags 28. Thus, the soccer helmet10 has flexibility crown-to-back. The side-to-side and crown-to-backflexibilities of the soccer helmet 10 allow the shell layer 14 to adjustin circumference to the shape of the human head (H). The restoring forceof the shell layer 14 causes the soccer helmet to hug the human head(H). Thus, the soccer helmet 10 maintains its position even afterheading a soccer ball. Thus, the soccer helmet 10 does not need to beadjusted very often, if at all, during soccer play.

[0031] The shell layer 14 and padding layer 12 have numerous ventilationholes formed therein as shown in FIG. 1 to allow for heat and moisturedissipation. Even with the ventilation holes, the soccer helmet 10 stillprovides significant protection in the areas having the ventilationholes. However, the areas of the soccer helmet 10 covering the crown,forehead and temples of the human head (H) lack ventilation holesthereby maximizing protection for areas subject to a higher risk ofinjury. The shell layer 14 is high enough over the ear that the ear doesnot contact the shell layer 14 during normal soccer play. A large widehole in the minor arcuate portions 12 c, 14 c of the padding layer 12and shell layer 14 allows a pony tail to extend through the back of thesoccer helmet 10.

[0032] Although shell layer 14 and padding layer 12 have ventilationholes or indentations, these holes or indentations are not large enoughto significantly affect the rebound direction of the soccer ball.Furthermore, shell layer 14 has no significant protrusions. A“significant” protrusion is defined as a protrusion from a surface thatmaterially affects the rebound direction of the soccer ball. In thisdescription and in the claims, a surface that lacks significantprotrusions is termed “smooth” even if the surface has holes that do notmaterially affect the rebound direction of the soccer ball.

[0033] The soccer helmet 10 also includes a means for attaching theshell layer 14 to the padding layer 12. The means may include apermanent attachment means such as adhesion or co-molding the paddinglayer 12 and shell layer 14 together as a composite material. However,in the embodiment shown in the figures, the shell layer 14 is removablyattached to the padding layer 12 allowing the padding layer 12 to bewashed or replaced.

[0034] Specifically, as seen in FIG. 2, a Velcro™ compatible looplaminate 16 is laminated to the outer surface of the padding layer 12with the loop side facing the inside surface of the shell layer 14. Theloop laminate 16 may be supplied by Veltex Industries, Inc. located inChino Hills, Calif.

[0035] A Velcro™ sheet 18 is adhered to the inside surface of the shelllayer 14 with the hook side of the Velcro™ sheet 18 facing the loop sideof the loop laminate 16. When the Velcro™ sheet 18 contacts the looplaminate 16, the shell layer 14 is attached to the padding layer 12.However, a reasonable amount of force will detach the Velcro™ sheet 18from the loop laminate 16 thus detaching the shell layer 14 from thepadding layer 12. Thus, the padding layer 12 may be interchangeable witha padding layer having different energy absorption characteristics tofit the user's preferences. For example, a ¼ inch polyolefin foam mayreplace the ⅜ inch polyolefin foam. The force required to remove thepadding layer 12 is greater than that experienced when a soccer ball isheaded with the soccer helmet 10, thus preventing detachment duringnormal soccer play.

[0036] A moisture management material 20 is attached to the insidesurface of the padding layer 12 by, for example, lamination or adhesion.The moisture management material 20 wicks perspiration from the humanhead (H) and dissipates heat and may be, for example, Hydrofil Dri-Lex2000 supplied by Faytex Corporation of Weymouth, Mass. A cross sectionof the padding layer 12, the shell layer 14, the loop laminate 16 andthe moisture management material 20 along cross section line 3-3 of FIG.1 is shown in FIG. 3. Although the Velcro™ sheet 18 is attached to theloop laminate 16 in some areas, it is not attached in the cross-section3-3 of FIG. 1.

[0037] Referring again to FIG. 2, The chin strap 22 has two pieces 22 a,22 b, each having one end attached to either the padding layer 12 orshell layer 14. FIG. 4 is a detailed diagram of portion 4 of FIG. 1showing an end of the chin strap piece 22 a sewn to the padding layer12. Alternatively, the ends of the chin strap pieces 22 a, 22 b may beinserted molded with the shell layer 14. The chin strap 22 may becomposed of a stretching, form-fitting material such as Lycra or may bea conventional non-stretching material. A Velcro™ piece 24 attaches theother end of the strap pieces 22 a, 22 b to each other under the chinthereby securing the soccer helmet 10 to the human head (H).

[0038] Referring to FIG. 1, a high friction material 26 may be providedon the forehead portion of the shell layer 14 thus slowing or haltingrotation of the soccer ball when contacting the forehead during aheader. Thus, the soccer ball may be better controlled.

[0039] The present invention may be embodied in other specific formswithout departing from its spirit or essential characteristics. Thedescribed embodiments are to be considered in all respects only asillustrative and not restrictive. The scope of the invention is,therefore, indicated by the appended claims rather than by the foregoingdescription. All changes which come within the meaning and range ofequivalency of the claims are to be embraced within their scope.

What is claimed and desired to be secured by United States LettersPatent is:
 1. A soccer helmet comprising: a generally dome-shapedpadding layer having inside and outside surfaces; and a generallydome-shaped shell layer having inside and outside surfaces, wherein theinside surface of the shell layer is attached to the outside surface ofthe padding layer, wherein the outside surface of the shell layer issmooth such that, when the soccer helmet is being work on a human head,a soccer ball rebounding off the shell layer rebounds in substantiallythe same direction as the soccer ball would rebound if reboundeddirectly from the human head, wherein the shell layer has a resiliencysuch that, when the soccer helmet is being worn on the human head, thesoccer ball rebounds off the shell layer with substantially the samespeed or more as the soccer ball would rebound if rebounded directlyfrom the human head.
 2. The soccer helmet of claim 1 , furthercomprising: means for securing the padding layer and shell layer to thehuman head.
 3. The soccer helmet of claim 1 , wherein the generallydome-shaped padding layer has a substantially uniform thickness.
 4. Thesoccer helmet of claim 1 , wherein the generally dome-shaped paddinglayer has a substantially uniform thickness at an area corresponding tothe temple and crown of the human head.
 5. The soccer helmet of claim 1, wherein the generally dome-shaped padding layer has a thickness ofapproximately ⅜ inches.
 6. The soccer helmet of claim 1 , wherein thegenerally dome-shaped padding layer has a thickness of approximately ⅜inches at an area corresponding to the temple and crown of the humanhead.
 7. The soccer helmet of claim 1 , wherein the generallydome-shaped shell layer comprises: a major portion for covering aforehead and crown of the human head; and a minor portion for covering arearward portion of the human head, wherein the major portion isflexibly coupled to the minor portion.
 8. The soccer helmet of claim 7 ,wherein the minor portion of the generally dome-shaped shell layer is afirst minor portion of the dome-shaped shell layer, the generallydome-shaped shell layer further comprising: a second minor portion forcovering an intermediate portion of the human head between the crown andthe rearward portion of the human head, wherein the second minor portionis flexibly coupled to the first minor portion and to the major portion.9. The soccer helmet of claim 8 , wherein the first and second minorportions of the generally dome-shaped shell layer define holes, whereinthe padding layer defined corresponding holes such that ambient aircontacts the human head through the holes when the soccer helmet is wornon the human head.
 10. The soccer helmet of claim 8 , wherein the firstminor portion of the shell layer defines a hole, wherein the paddinglayer defines a corresponding hole sized such that a pony tail from thehuman head can fit through the hole.
 11. The soccer helmet of claim 1 ,further comprising means for attaching the generally dome-shaped shelllayer to the generally dome-shaped padding layer.
 12. The soccer helmetof claim 1 , further comprising: a Velcro™ compatible loop materialcoupled to one of the shell layer or padding layer; and a Velcro™ sheetcoupled to the other of the shell layer or padding layer, wherein theshell layer is attached to the padding layer by contacting the loopmaterial with the sheet.
 13. The soccer helmet of claim 1 , furthercomprising a chin strap coupled to one of the padding layer or shelllayer for securing the padding layer and shell layer to the human headwhen the soccer helmet is worn on the human head.
 14. The soccer helmetof claim 1 , wherein the padding layer is removably attached to theshell layer.
 15. The soccer helmet of claim 1 , wherein the paddinglayer comprises closed cell foam.
 16. The soccer helmet of claim 1 ,wherein the outer surface of the shell layer is smooth at an areacorresponding to a human forehead.
 17. A method comprising: forming asoccer helmet padding layer, the padding layer having a uniformthickness at an area corresponding to a forehead; forming a soccerhelmet shell layer shaped to fit over the soccer helmet padding layer;and attaching the soccer helmet shell layer to the soccer helmet paddinglayer.
 18. A method comprising: attaching a soccer helmet padding layerto a soccer helmet shell layer; and removing the soccer helmet paddinglayer from the soccer helmet shell layer.